Recycling centres are demanding workplaces. Forklifts operate alongside lorries, bins, cages, and pedestrians, often in outdoor, uneven environments. Without strict safety measures, incidents are almost inevitable. This case study shows how one Midlands recycling facility turned its forklift safety record around with training, layout changes, and stronger PPE culture.
The Challenge
The site processed over 200 tonnes of mixed materials daily. Forklift operators reported frequent near misses, including:
- Forklifts skidding on wet surfaces
- Poor visibility in dusty areas
- Pallets and bins toppling due to poor stacking
- Pedestrians straying into forklift zones
In one six-month period, the facility logged 12 minor accidents and over 40 near misses. Productivity was slowing, and morale was low.
The Solution
Management partnered with RS Forklift Training to deliver a full forklift safety review, including:
1. Targeted Forklift Training Refreshers
Every operator completed an RTITB-accredited refresher course tailored to recycling environments. Training focused on:
- Handling irregular loads
- Working on uneven ground and gradients
- Low fork travel and stable stacking
- Communication and signals in noisy yards
2. Layout Improvements
The yard was reorganised to separate forklift and pedestrian zones, with clear one-way systems and marked marshalling points. Convex mirrors were installed at blind corners, and slopes were restricted to uphill/downhill travel only.
3. PPE and Safety Culture
PPE requirements were tightened and enforced consistently. New signage reminded staff of hi-vis, boots, gloves, and eye protection. Supervisors led by example and performed daily safety walkarounds.
4. Daily Checks and Briefings
Operators introduced daily pre-use checks with a simple tick-sheet. Morning toolbox talks included weather conditions, known hazards, and updates on site changes.
The Results
- Near misses reduced by 75% in the first three months.
- No accidents logged in the following six months.
- Productivity improved as operators moved confidently through clear lanes with fewer delays.
- Morale increased — staff reported feeling safer and more respected.
Operator Feedback
One forklift operator commented: “Before, every shift felt like a risk. Now I know the layout, I know the rules, and I’ve had proper training for our yard. It’s safer and less stressful.”
Lessons for Other Facilities
This case study highlights simple but effective actions any recycling site can take:
- Invest in refresher training tailored to your environment.
- Redesign layouts with clear zones and flow to minimise conflicts.
- Make PPE use consistent and visible, led by supervisors.
- Use daily briefings to keep safety at the front of everyone’s mind.
Conclusion
Recycling facilities will always be high-risk, but they don’t have to be unsafe. With training, layout changes, and a strong PPE culture, forklift teams can work efficiently and confidently. If you want to transform your own facility’s safety record, contact RS Forklift Training in Birmingham today for practical, accredited forklift training that matches your environment.
